Hinge for passing electrical current

ABSTRACT

A hinge for passing electrical current includes two adjacent hinge knuckles arranged on different pin-connected leaves and formed to afford a recess in the interior of the hinge. Passages connect the recess with exterior surfaces of the hinge leaves, thus completing a continuous passage through the hinge into which one or more electrical wires are threaded. The continuous passage preferably communicates with the rear surfaces of the leaves such that the electrical wire is substantially hidden from view when the hinge is installed, giving the outward appearance of a conventional hinge.

United States Patent [1 1 Suska I 1 HINGE FOR PASSING ELECTRICAL CURRENT[75] Inventor: Charles R. Suska, Roxbury, Conn.

[73] Assignee: The Stanley Works, New Britain,

Conn.

[22] Filed: Nov. 21, I973 [21] Appl. No.: 418,022

Related US. Application Data [63] Continuation of Ser. No. 273,483, July20, I972,

abandoned.

[52] US. Cl. 339/4, 174/86 [51] Int. Cl l-l02g 11/00 [58] Field ofSearch 339/4; 310/71; 174/86 [56] References Cited UNITED STATES PATENTS352,596 l1/1886 Wilson 339/4 3,428,738 2/1969 Zychal 339/4 X FOREIGNPATENTS OR APPLICATIONS Great Britain 339/4 1 Oct. 15, 1974 PrimaryExaminer-James D. Trammell Attorney, Agent, or Firm-Brumbaugh, Graves,Donohue & Raymond 7] ABSTRACT A hinge for passing electrical currentincludes two adjacent hinge knuckles arranged on different pinconnectedleaves and formed to afford a recess in the interior of the hinge.Passages connect the recess with exterior surfaces of the hinge leaves,thus completing a continuous passage through the hinge into which one ormore electrical wires are threaded. The continuous passage preferablycommunicates with the rear surfaces of the leaves such that theelectrical wire is substantially hidden from view when the hinge isinstalled, giving the outward appearance of a conventional hinge.

6 Claims, 5 Drawing Figures SHEEY 2 0F 2 PAIENTEDncI 1 51914 HINGE FORPASSING ELECTRICAL CURRENT This is a continuation, of application Ser.No. 273,483, 7-2072, now abandoned.

HISTORY OF THE INVENTION Recent concern with building safety andsecurity has led to the development of many electrically operateddevices to protect life and property. A typical safety device is a doorholder which automatically releases the door when an associated sensordetects smoke or heat.

jamb to the door at the most convenient point to minimize the length ofexposed wire. Unconcealed wiring is an obvious indication to an intruderthat the door is electrically connected 'in some manner and also exposesthe electrical connection to destruction or damage from an intruder,fire or normal operation of the door.

SUMMARY OF THE INVENTION The present invention relates to a new andunique hinge which conveniently passes electrical current from a doorframe to a door in a protected, inconspicuous and aestheticallypleasing'manner. To accomplish this result, electrical wires are hiddeninside the hinge, entering and leaving through the rear surfaces of thehinge leaves, which face the door and jamb when the hinge is installed.

The hinge includes two hinge leaves and at least two associated hingeknuckles connected byat least one hinge pin. These elements are formedto provide a recess in the interior of the hinge.

Passages communicate with the recess and extend radially outward fromthe central pivotal axis of the hinge through the leaves to theirexterior surfaces, thereby completing a continuous passage through thehinge. The continuous passage preferably communicates with the rearsurfaces of the leaves.

To pass electricity through the hinge, a small diameter flexible wire orwires are inserted into the opening in one leaf, threaded through theassociated radial passage communicating with the recess, passed throughthe recess, and then threaded through the radial passage in the otherhinge leaf. Thus, when the hinge is properly installed on a door mountedin a door frame, the electrical wiring will be invisible to an observer.

BRIEF DESCRIPTION OF THE DRAWINGS For a better understanding of theinvention, reference may be made to the following description of threeexemplary embodiments, taken in conjunction with the figures of theaccompanying drawing, in which:

FIG. 1 is a front view of a hinge arranged according to the invention,partly broken away to show the recess in the hinge;

FIG. 2 is an enlarged sectional view of the hinge of FIG. 1, taken alongview line 2-2;

FIG. 3 is a partial front view of a second embodiment of the invention;

FIG. 4 is a front view of a third embodiment of the invention, partlybroken away to show the recess in the hinge; and

FIG. 5 is an enlarged sectional view of the hinge of FIG. 4, taken alongview line 4-4.

DESCRIPTION OF THE INVENTION In an exemplary embodiment of theinvention, as shown in FIGS. 1 and 2, a hinge comprises a pair ofadjacent hinge leaves 10 and 12, each having a plurality of holes 13 forreceiving mounting screws and at least one annular hinge knucklearranged along its edge adjacent the other hinge leaf. In thefive-knuckle hinge depicted in the drawings, three spaced-apart knucklesl4, l6 and 18 are arranged on hinge leaf l0 and two spaced-apartknuckles 20 and 22 are arranged on leaf l2, fitting between the knuckles14, I6 and I8 on leaf 10. The knuckles 14, l6, I8, 20 and 22 are axiallyalignable and londitudinally closely spaced, such that a hinge pinassembly, generally designated 24, may be received within the knucklesto secure them in axial alignment, while permitting relative pivotalmovement about a common axis. Hinge pin assembly 24 may be of anyconvenient construction. As shown in FIG. 1, it consists of an elongatedand generally cylindrical pin 26 and two associated tip members 28,which fit over the ends of the pin 26. The tip members 28, which includelaterally extending flanges 30, extend into the bore formed by thealigned hinge knuckles, the flanges 30 contacting the exposed ends ofhinge'knuckles 14 To permit the wires 36 to extend from one hinge leafto the other, as shown inFIG. l, a passage 37 is pro vided in hinge leaf10 by drilling a hole through the thickness of the leaf 10 into thehinge knuckle 16 from an exterior edge 38 of the leaf. It will beunderstood that this method of providing the passage 37 is merelyexemplary and that other methods may be used. As best shown in FIG. 2, acommunicating passage 40 is drilled perpendicular to the axis of thepassage 37 and the plane of the rear surface 42 of the leaf 10.Similarly, a passage 44 is drilled through the hinge leaf 12 to theknuckle 20 from an exterior leaf edge 46. A communicating passage 48,drilled into the rear surface 50 of the leaf 12, extends perpendicularlyto that surface and the axis of passage 44. The passage 37, 40 and thepassage 44, 48 may communicate with rear surfaces 42 and 50 at anyconvenient point, but a central location, as shown in the drawings,provides maximum protection.

Withthe foregoing arrangement, the electrical wires 36 are concealed asthey emerge from the hinge leaves and, in addition, are protected fromdamage by intruders. Note also that the wires 36 may be carried inpassages resulting from U-shaped slots milled in the rear surfaces ofthe leaves.

The insulated wires 36 are preferably of small diameter and flexible. Awire found satisfactory is fabricated of fine strands of wire, forexample, 19 strands of 38 AWG copper, and has 0.005 inch thick extrudednylon insulation and an overall diameter of 0.030 inches. As shown inthe drawings, two wires are received in the continuous passage throughthe hinge formed by the passages and recess of the hinge and may bewound around the hinge pin 26 as they pass from one hinge leaf to theother. The conductors 36 are wound loosely enough to permit one hingeleaf to pivot relative to the other through 270 without undue strain onthe wires 36 or their insulation, and tightly enough to prevent unduerubbing contact between the wires and the interior surfaces of the hingeknuckles 16 and 20, which might damage and short circuit them. It isoften preferred, however, for the wires 36 to pass through the recess 33without being wound around the hinge pin 26, as shown in FIG. 3 anddescribed hereinafter.

While the wires will generally be insulated, in the event a ground wireis used, or a nonconductive hinge material employed, one or more of thewires may be uninsulated.

Where the wires 36 emerge from the rear surfaces 42 and 50 of the hingeleaves and 12, they may be embedded in any appropriate protectivematerial 54-, such as an epoxy resin, as shown in FIG. 2, to hold thewires 36 securely in place and prevent them from contacting the edges ofthe passages 40 and 48,,thereby further protecting the wires.

A second embodiment of the invention is shown in FIG. 3, wherein only asingle counterbore 32' in hinge knuckle 16 forms an annular recess 33',and a passage 44' in hinge leaf 12 communicates directly withcounterbore 32 rather than through a counterbore in hinge knuckle Theelectrical wires 36 are not wound around the pin 26, although they maybe so arranged, but are simply passed along the recess 33' with lessthan a full turn around the pin. Moving the leaves 10 and 12 will, orcourse, tend to cause some coiling of the wires 36. This arrangement ofthe wires 36 takes advantage of technological advances in insulatedflexible electrical wires. In particular, presently available wires areformed of fine strands of conductive wire and encased in a thin sheathof insulation that has high electrical resistance, excellent resistanceto aging, good flexi- 'bility over a wide temperature range, andexcellent abrasion resistance.

FIGS. 4 and 5 of the drawings show a third embodiment of the inventionin which the hinge pin 26 of FlGS. 1, 2 and 3 has been replaced by twoshorter pins. The hinge comprises a pair of hinge leaves 56 and 58, eachhaving a plurality of holes 60 for receiving mounting screws. Threespaced-apart knuckles 62, 64 and 66 are arranged on the hinge leaf 58and two spaced-apart knuckles 68 and 70, arranged on the leaf 56, fitbetween them. The knuckles 68, 64 and 70 are closely spaced, butknuckles 62 and 68, and 66 and 70, are separated to receive ballbearings 72. Each bearing .72 is formed with a flange 74 projecting intoa counterbore 76 formed in an end of the adjacent knuckle.

Two identical hinge pins 78 are axially received within hinge knuckles62 and 68, and hingeknuckles 66 and 70, extending only part way throughhinge knuckles 68 and 70. The pins 78, knurled for a portion of theirlengths to hold them in position, are generally cylindrical. withlaterally extending flanges 80 at one end that provide functional anddecorative caps for the ends of the hinge knuckles 62 and 66.

As shown in FIG. 4, counterbores 82 and 84 are provided in centrallylocated hinge knuckles 64 and 68 to afford an enlarged recess 86 forreceiving one or more electrical wires 88. Note that it may be desirableto use the recess afforded by the existing bores, without enlargement,in the knuckles 64 and 68 to form part of the continuous passage throughthe hinge for the electrical wires 88. As in previous embodiments of theinvention. passages 90 and 92 in hinge leaves 56 and 58 permit theconductors 88 to extend through the hinge from one leaf to the other.Communicating passages 94 and 96 extend from the passages 90 and 92 tothe rear surfaces 98 and 100 of the leaves 56 and 5 8.

The wires 88 are received in the continuous passage formed through thehinge in the manner of the embodiment of FIG. 3. Where the conductors 88emerge from the rear surfaces 98 and 100 of hinge leaves 56 and 58, theymay be embedded in any appropriate protective material 102, such asepoxy resin, as previously discussed.

It will be understood that the above-described embodiments are merelyexemplary and that those skilled in the art may make many variations andmodifications without departing from the spirit. and scope of theinvention. All such modifications and variations are intended to bewithin the scope of the invention as defined in the appended claims.

I claim:

l. A load bearing hinge for mounting a a door in a door frame andfor'passing electrical current between the door and frame through aconcealed and tamperproof electrical wire comprising a pair of adjacentflat hinge leaves of substantially uniform thickness having frontandrear exterior surfaces, openings in the leaves to secure them to thedoor and frame with their rear surfaces abutting the door and frame, atleast two axially aligned and closely spaced hinge knuckles, one of saidknuckles extending from each adjacent leaf edge, at least one hinge pinaxially received in said knuckles to secure them in axial alignmentwhile permitting relative pivotal movement about said aligned axes,means providing a recesswithin at least one of the knuckles, a concealedtunnel in each leaf generally parallel to the front and rear exteriorsurfaces thereof and extending through the knuckle associated with theleaf to said recess, an opening in the rear exterior surface of eachhinge leaf communicating with the corresponding tunnel in the leaf, theopenings in the rear exterior surfaces of the leaves being sufficientlyspaced from their respective knuckles by said tunnels to permit theopenings to be hidden from view by the door and door frame when thehinge is installed on the door and door frame, the hinge when installedgiving the outward appearance of a conventional load bearing door hinge,a continuous and concealed passage from the rear exterior surface ofonehinge leaf to the rear exterior surface of the other hinge leaf beingformed by the two openings in the hinge leaves, the tunnels in theleaves and the recess, and at least one electrical wire threaded throughthe continuous passage for conducting electrical current through thehinge and concealed from view and protected from damage by the hingeleaf material and knuckle material when the hinge is mounted on the doorand door frame.

2. A hinge according to claim 1, wherein said recess providing meanscomprises bores formed in adjacent ends of the two adjacent hingeknuckles.

. 3 ,842,3 86 5 6 3. A hinge according to claim 1, wherein said recesspin extends through said recess, and the electrical wire providing meanscomprises a bore formed in one of the is threaded through the continuouspassage with at two adjacent hinge knuckles. least one turn around thehinge pin in the recess.

4. A hinge according to claim 1, wherein said at least 6. A hingeaccording to claim 1, wherein the hinge one hinge pin includes twolongitudinally spaced apart 5 pin extends through the recess, and theelectrical wire hinge pins, and said recess is formed betweenlongitudiis threaded through the continuous passage with less nallyspaced ends of said two hinge pins. than one turn around the hinge pinin the recess.

5. A hinge according to claim 1, wherein the hinge 33 UNITED STATESPATENT OFFICE CERTIFICATE OF CORRECTION patent 3,842 ,386 Dated October15, 1974 lnventofl l) Charles R. Suska It is certified that errorappears in the above-identified patent and that said Letters Patent arehereby corrected as shown below:

Column 2, line 58, insert after the period -Moreover, the installed loadbearing door hinge gives the outward appearance of a conventional loadbearing hinge so that intruders are not forewarned of the electricalwiring.-; Column 3, line 36, "or course" should be of course-; andColumn 4, line 28, "a a door" should be --a door-.

Signed and sealed this 11th day of February 1975.

(SEAL) Attest:

C. MARSHALL DANN RUTH C. MASON Commissioner of Patents Attesting Officerand Trademarks mg UNITED STATES PATENTCFFICE CERTIFICATE OF CORRECTIONPatent NO. 318421386 Dated October 1974 l wencoflfl) Charles R. Suska Itis certified that error appears in the above-identified patent and thatsaid Letters Patent are hereby corrected as shown below:

Column 2, line 58, insert'after the period -Moreover, the

installed load bearing door hinge gives the outward appearance of aconventional load bearing hinge so that intruders are not forewarned ofthe electrical wiring.--; Column 3, line 36, "or course" should be -ofcourse--; and Column 4, line 28, "a a door" should be --a door-.

Signed and sealed this 11th day of February 1975;

(SEAL) Attest:

C. MARSHALL DANN RUTH C. MASON Commissioner of Patents Attesting Officerand Trademarks

1. A load bearing hinge for mounting a a door in a door frame and forpassing electrical current between the door and frame through aconcealed and tamper-proof electrical wire comprising a pair of adjacentflat hinge leaves of substantially uniform thickness having front andrear exterior surfaces, openings in the leaves to secure them to thedoor and frame with their rear surfaces abutting the door and frame, atleast two axially aligned and closely spaced hinge knuckles, one of saidknuckles extending from each adjacent leaf edge, at least one hinge pinaxially received in said knuckles to secure them in axial alignmentwhile permitting relative pivotal movement about said aligned axes,means providing a recess within at least one of the knuckles, aconcealed tunnel in each leaf generally parallel to the front and rearexterior surfaces thereof and extending through the knuckle associatedwith the leaf to said recess, an opening in the rear exterior surface ofeach hinge leaf communicating with the corresponding tunnel in the leaf,the openings in the rear exterior surfaces of the leaves beingsufficiently spaced from their respective knuckles by said tunnels topermit the openings to be hidden from view by the door and door framewhen the hinge is installed on the door and door frame, the hinge wheninstalled giving the outward appearance of a conventional load bearingdoor hinge, a continuous and concealed passage from the rear exteriorsurface of one hinge leaf to the rear exterior surface of the otherhinge leaf being formed by the two openings in the hinge leaves, thetunnels in the leaves and the recess, and at least one electrical wirethreaded through the continuous passage for conducting electricalcurrent through the hinge and concealed from view and protected fromdamage by the hinge leaf material and knuckle material when the hinge ismounted on the door and door frame.
 2. A hinge according to claim 1,wherein said recess providing means comprises bores formed in adjacentends of the two adjacent hinge knuckles.
 3. A hinge according to claim1, wherein said recess providing means comprises a bore formed in one ofthe two adjacent hinge knuckles.
 4. A hinge according to claim 1,wherein said at least one hinge pin includes two longitudinally spacedapart hinge pins, and said recess is formed between longitudinallyspaced ends of said two hinge pins.
 5. A hinge according to claim 1,wherein the hinge pin extends through said recess, and the electricalwire is threaded through the continuous passage with at least one turnaround the hinge pin in the recess.
 6. A hinge according to claim 1,wherein the hinge pin extends through the recess, and the electricalwire is threaded through the continuous passage with less than one turnaround the hinge pin in the recess.